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product description
Busbar system – trolley line TR60 and TR85 Giovenzana page 44 to 67
The “trolley system” series conductors rails are modern and safe system for energy and data transmission for various types of equipment such as: cranes - bridge cranes - conveyour belts - chain conveyors - etc...The “trolley system” complies with the relevant international standards ensuring operator safety, easy of installation and reliability.
Typical line schematic
ID Name Function
① Busbar PVC housing
② Trolley transmit the energy from the conductor to the load
③ Feed connect power supply to the conductors
④ Joint / Fixed point connect two busbars / create a fixed point
⑤ End Cap close and protect the busbar end
⑥ In-line feed avoid the voltage reduction
⑦ Hanger clamp connect the busbar to the brackets
⑧ Copper strip transmit the energy from the power supply to the trolley
Busbar line exampleand
module type
Straight : 3 or 4 meter module
90° curvestandard radius available orcustomized radius on request
Height drop available on request
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�Worldwide installation: complies with the relevantinternational standards.� Safety: the conductors are protected and insulated bythe busbar.� Extra quality materials: self-extinguishing and high resistant strenght.� Easy & Fast installation: only a simple “click” (NO toolsrequired) is needed to mount almost all items.� Flexible: indoor or outdoor installation, all componentsare designed to tolerate different climate status.� Expansion possibilities: a lot of possibilities to expandor customize your line
Busbar systemEnergy and data transmission
versions
Exploded & sectionview
45
Exploded & sectionview
Yellow colour
CONTINUOUS CONDUCTORS: the conductors strip are pulled from a coil without jointsinto the already installed casing.
long life, minimal and constant voltage reduction! The absence of joints between the
conductors permits a long life brushes, plus minimal deposit and ohmmic resistance.
Versions
Blue colour
PRE-MOUNTED CONDUCTORS: the conductors are already inserted in the plastic casing.
very fast installation! Since the conductors are already inserted into the housing, it is only
necessary to joint each section of the busbar.
Busbar systemEnergy and data transmission
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joint
withoutjoint
size
46
Size
� TR60 40 - 60 amp � TR85 40 – 70 – 100 – 140 - 200 amp
Conductor’s slot (max 5)
Gasket’s slot (option)
Power supply
Type ID
Phase R/L1
Phase S/L2
Phase T/L3
Neutral N
Ground PENote: PE conductor ID marked on busbar side
Scale 1:1 Scale 1:1
One way trolley insertion pin
56
85
60
402.7
4
17
11
Busbar systemEnergy and data transmission
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Line constructionBusbar systemEnergy and data transmission
47
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Line construction
To decide the size of trolleys is necessary to consider:� Maximum current in service� Devices (cage motors, slip rings motors, resistors, electronic starters)� Starting current of the devices� Maximum ambient temperature� The distance between device to the nearest power feed� Voltage and admissible voltage drop in continuous and in starting service� Type of current� Devices cycle operations (load factor)
Calculation of the voltage drop
Voltage drop should not exceed 5% of rated voltage in normal operating service
Three phase alternate current: Legenda:
∆u∆u%
ILtZU
======
voltage dropvoltage dropcurrent intensitylenght of sectionimpedencevoltage
[V][%][A][m][Ω/m][V]
Power feed: busbar track length
A proper disposal of power feed points minimize the voltage reduction.If “L” is the lenght of the line, “Lt” is the track maximum length to consider the voltage reduction.
ABCD
LtLtLtLt
====
LL/2L/6
L/10
with ending/starting power feedwith in-line power feedwith power feed at 1/6 from each endwith three power feed at L/2 and L/10 from each end
A B
C D
Line constructionBusbar systemEnergy and data transmission
48
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Current in continuous service
Specify the number of the devices which work simultaneously to calculate the corresponding current:
In = I1 + I2 + I3 + ….
The current can be determined from the devices power [W] that for a three phase system is:
Legenda:
InPuȠU
cosϕ
=====
current consumptionpower devicesdevices performanceoperating voltagepower factor
[A][W]
[V]
In the absence of information on the operation of simultaneous devices, consider the following table:
Numbers of in-line lifting device
Lifting equipment in use
1st engine 2nd engine 3rd engine 4th engine
max power engine (○) decreasing power engine (○)
1 X X
2 X X X
3 X X X
4 X X X X
5 X X X X
No. 2 lifting equipmentoperating simultaneously
X X X X
(○) about Ƞ motors connected in parallel with rated current In’, consider In = Ƞ ● In’
Starting current
Calculate the numbers of the devices started simultaneously and the device already in service, then calculate the corresponding current. If the starting current is unknown, proceed with the following approximation:
for a single user
as a general rule, consider:K = 5 to 6 for cage motorsK = 2 for winding motorsK = 2 for inverters (frequency converters)
In the absence of information on the operation of simultaneous devices, consider the following table:
Numbers of in-line lifting device
Lifting equipment in use
1st engine 2nd engine 3rd engine 4th engine
Ia In Ia In Ia In Ia In
1 X X
2 X X X
3 X X
4 X X X
5 X X X X
No. 2 lifting equipmentoperating simultaneously
X X X X
Other items
Power feed from 40A to 140A TR8503A4 1
End cap from 40A to 200A TR8506A 1
Hanger clamp from 40A to 140A plastic material TR8502 (○) 17
Hanger clamp from 40A to 140A steel material TR8525 (○) 17
Joint from 40A to 200A plastic material
(the quantity of the joints is equal to the quantity of the
busbar +1)
TR8504 (○) 10
(○) add no. 2 hanger clamp for R.1200 to 1.800mm curve
add no. 3 hanger clamp for R.2.200mm curve
Curve
Curve R.2.200mm = L 3.455mm TR8529704D90 1
Curve R.1.200mm = L 1.885mm TR8529704A90 1
Total busbar lenght: ① + ② + ③ sector = 31m
Total busbar 4m module TR85704C 4
Total busbar 3m module TR85704C3 5
③ section 7,0m = 7.000mm
15.250-290 (end cap) = 14.960mm
No.3 busbar 4m = 12.000mm
No.1 busbar 4m = 4.000mm TR85704C 1
No.1 busbar 3m = 3.000mm TR85704C3 1
7.000mm – 7.000mm = 0
② section 8,750 = 8.750mm
No. 3 busbar 3m = 9.000m TR85704C3 3
9.000mm – 8.750mm = +250mm (excess)
TR85 BLUE line exampleBusbar systemEnergy and data transmission
49
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① section 15,250m = 15.250mm
15.250-85 (power feed) = 15.165mm
No.3 busbar 4m = 12.000mm
No.3 busbar 4m = 12.000mm TR85704C 3
No.1 busbar 3m = 3.000mm TR85704C3 1
12.000mm+3.000mm = 15.000mm-15.165 = -165mm (lack)
TR85 Blue line (pre-mounted conductors) 70 A – 4 conductors, order example:
To define line overall length is necessary to consider the standard modular length of the busbar, except the curves.These can be obtained with the 3 or 4 meters module.The real length of the line will therefore be highter or lower than the theoretical length assumed or required.
Example of order and composition of a line according to the diagram:
Busbar systemEnergy and data transmission Code Map
50
ID Name Function Specifications 40 A 60 A 40 A 60 A
① Busbar PVC housing
3 meters module 4 conductors
-
TR60404C3 TR60604C3
3 meters module 5 conductors TR60405C3 TR60605C3
4 meters module 4 conductors
TR6000 (w/o conductors)
TR60404C TR60604C
4 meters module 5 conductors TR60405C TR60605C
Curved 90° (□)R.1.2 meters
4 conductorsTR60A90 TR60404A90 TR60604A90
Curved 90° (□)R.1.5 meters
4 conductorsTR60B90 TR60404B90 TR60604B90
Curved 90° (□)R.1.8 meters
4 conductorsTR60C90 TR60404C90 TR60604C90
Curved 90° (□)R.2.2 meters
4 conductorsTR60D90 TR60404D90 TR60604D90
② Trolleytransmit the energy from the
conductor to the load
4 conductors TR6004 (25 A)
5 conductors TR6005 (25 A)
③ Feedconnect power supply to the
conductors
4 conductors
TR6003
TR6003A4
5 conductors TR6003A5
④Joint / Fixed
pointconnect two busbars / create a
fixed point
Joint TR6001 (PA66)
Fixed point TR6014
⑤ End Cap close the busbar end TR6006 TR6006A
⑥ In-line feed avoid the voltage reduction
4 conductors
TR6008
TR6008A4
5 conductors TR6008A5
⑦ Hanger clampconnect the busbar to the
bracketsPA66 material
TR6002 (PA66) – TR6020 (steel)every 1.33 meter max
⑧ Copper striptransmit the energy from the
power supply to the trolleyCS40 CS60 -(copper strip already inserted)
- Support bracket support the line
Rail fixing
L 350mm TR8550
L 500mm TR8551
L700 mm TR8552
Wall fixing
L 350mm TR8555
L 500mm TR8556
- Towing armfixed to the mobile device
permits to tow the trolleysTR8510
-Towing arm
bracketpermits to the mobile device to
tow the trolleyTR6007
-Double trolley
supportconnects two trolley in parallel
to increase current ratingTR6013
- Gasket IP23 additional protection IP13>IP23 TR6012
-Copper strip
trolley insertionspecific tool to insert easily the
copper strip into the busbarTR6011 - (copper strip already inserted)
- De-coil unit unwind easily the copper rolls TR8513 - (copper strip already inserted)
- Inspection joint allow easy trolley’s replacement - -
- Section joint Isolate two side track -
- Brushes spare parts - - - -
TR60
YELLOW line BLUE line
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Busbar systemEnergy and data transmission Code Map
51
70 A 100 A 140 A 40 A 70 A 100 A 140 A 200 A
- - - TR85404C3 TR85704C3 TR851004C3 TR851404C3 TR852004C3
- - - TR85405C3 TR85705C3 TR851005C3 TR851405C3 TR852005C3
TR85704 (*) TR851004 (*) TR851404 (*) TR85404C TR85704C TR851004C TR851404C TR852004C
TR85705 (*) TR851005 (*) TR851405 (*) TR85405C TR85705C TR851005C TR851405C TR852005C
TR8529A90 TR8529404A90 TR8529704A90 TR85291004A90 TR85291404A90 -
TR8529B90
(R. 1400mm)
TR8529404B90
(R. 1400mm)
TR8529704B90
(R. 1400mm)
TR85291004B90
(R. 1400mm)
TR85291404B90
(R. 1400mm)-
TR8529C90 TR8529404C90 TR8529704C90 TR85291004C90 TR85291404C90 -
TR8529D90 TR8529404D90 TR8529704D90 TR85291004D90 TR85291404D90 -
TR8511 (35 A) / TR8518 (70 A) / TR8532 (70A articulated used for line with curved busbar)
TR8512 (35 A) / TR8519 (70 A)
TR8503
TR8503A4 TR8533A4
TR8503A5 TR8533A5
TR8501 (PA66) / TR8524 (steel) TR8504
TR8527.1
TR8506 TR8506A
TR8547
TR8502 (PA66 not for 200 A) / TR8525 (steel)every 2meters max from 40 to 140 amp - every 1 meter max for 200 amp
(*) (*) (*)- (copper strip
already inserted)
- (copper strip
already inserted)
- (copper strip
already inserted)
- (copper strip
already inserted)
- (copper strip
already inserted)
TR8550
TR8551
TR8552
TR8555
TR8556
TR8510
TR6007
TR8523
TR8505
TR8514 - (copper strip already inserted)
TR8513 - (copper strip already inserted)
TR8528 -
TR8545 TR8545B
TR8517 (35 A) / TR8520 (70 A)
TR85
YELLOW line BLUE line
(*) copper rolls already included in the busbar code(□) on request available other curve radius
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Busbar systemEnergy and data transmission TR60 series 40-60A
52
Blue linepre-mounted conductors
Yellow lineconductors to be pulled
min. qty
Name SpecificationsN°
conductors 40 A 60 A 40 A 60 A
Straightbusbar
� Self-extinguishing material� One-way trolley insertion pin.
←→L = length
Lmeters
34 TR60404C3 TR60604C3
-
3-4meters
5 TR60405C3 TR60605C3
44 TR60404C TR60604C
TR60005 TR60405C TR60605C
90°curvedbusbar
� Self-extinguishing material� One-way trolley insertion pin.
R = radius
Rmeters
1.2
4
TR60404A90 TR60604A90 TR60A90
11.5 TR60404B90 TR60604B90 TR60B90
1.8 TR60404C90 TR60604C90 TR60C90
2.2 TR60404D90 TR60604D90 TR60D90
Feed
�Fast assembly�M25 cable gland equipped
4 TR6003A4TR6003 1
5 TR6003A5
In-linefeed
�Fast assembly (+screw)�M25 cable gland equipped
4 TR6008A4TR6008 1
5 TR6008A5
End cap �Self tapping screw fix
4TR6006A TR6006 1
5
Copperstrip
-
-CS40
40 A /10mm²CS60
60 A /15mm² (○)
Note (○) “copper strip quantity”: will be supplied the total meters according busbar quantity
Click!
Click!
� TR60 40 amp60 amp
Code table list page 1/2
Dimensions see pag 58
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Busbar systemEnergy and data transmission TR60 series 40-60A
53
Blue linepre-mounted conductors
Yellow lineconductors to be pulled
min. qty
Name Picture Specifications note 40 A 60 A 40 A 60 A
Trolley25 A
� 25A load current�Self-extinguishing mat.�Fully insulated�Metal graphite brushes�One-way insertion pin�Easy cable wiring
4 conductors TR6004 1
5conductors
TR6005 1
Doubletrolley
support
�Connects two trolleys in parallel to increasecurrent rating
TR6013 1
Hangerclamp
�Fast connection�Every 1.33 meters MAX
PA66material
TR6002 1
Steelmaterial TR6020 1
Joint
�Fast assembly
TR6001 1
Fixedpoint
�Fast assembly
TR6014 1
Towingarm
Fixed to the mobile device permits to tow the trolley�Galvanizedsteel material
TR8510 1
Towingarm
bracket
Fixed to the trolley permits to the mobile device to tow the trolley�Painted blacksteel material
TR6007 1
GasketIP23
Additional prot. IP13>IP23�PVC material�Resistance to cold -30°�Stretching 340%�Hardness shore A 81
TR6012 (●)
Strip insertion
trolley
Specific tool to easily insert the copper strip into the busbar
- TR6011 1
De-coilunit
Specific tool to easily unwind the copper rolls - TR8513 1
Dimensions see pag 58
Click!
Click!
Note (●) “gasket IP23 quantity”: (for order please consider twice the length of the line)
Click!
� TR60 40 amp60 amp
Code table list page 2/2
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Busbar systemEnergy and data transmission TR85 series 40-70-100-140-200A
54
Blue linepre-mounted conductors
Yellow lineconductors to be pulled
min. qty
Nam
e
Specifications N°
cond
ucto
rs40 A 70 A 100 A 140 A 200 A 70 A 100 A 140 A
Stra
ight
busb
ar
� Self-extinguishingmaterial� One-way trolley insertion pin.
←→L = lenght
Lmeters
copper strip rolls already included in busbar code
34 TR85404C3 TR85704C3 TR851004C3 TR851404C3 TR852004C3 -
3-4meters
5 TR85405C3 TR85705C3 TR851005C3 TR851405C3 TR852005C3 -
44 TR85404C TR85704C TR851004C TR851404C TR852004C TR85704 TR851004 TR851404
5 TR85405C TR85705C TR851005C TR851405C TR852005C TR85705 TR851005 TR851405
90°c
urve
dbu
sbar
�Self-extinguishing material� One-way trolley insertion pin.
R = radius
Rmeters
1.2
4
TR8529404A90 TR8529704A90 TR85291004A90 TR85291404A90 - TR8529A90
11.4 TR8529404B90 TR8529704B90 TR85291004B90 TR85291404B90 - TR8529B90
1.8 TR8529404C90 TR8529704C90 TR85291004C90 TR85291404C90 - TR8529C90
2.2 TR8529404D90 TR8529704D90 TR85291004D90 TR85291404D90 - TR8529D90
Feed
�M40 cable gland equipped
4 TR8503A4 TR8533A4TR8503 1
5 TR8503A5 TR8533A5
In-li
nefe
ed
�Pg29 cable gland equipped (not mounted)
TR8547 1
End
cap
�Self-tapping screw fixing
TR8506A TR8506 1
Join
t
TR8504 TR8535 TR8501 (PA66) – TR8524 (steel)
Sect
ion
join
t �N°2 Pg29 cable gland equipped�Insulating strip bars
TR8545B TR8545
� TR85 40-70-100-140-200 amp Dimensions see pag 62
Code table listpage 1/2
200amp
70..140 amp
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Blue linepre-mounted conductors
Yellow lineconductors to be pulled
min. qty
Nam
e
Picture Specifications Note 40 A 70 A 100 A 140 A 200 A 70 A 100 A 140A
35A
trol
ley � 35 or 70 A load
current�Self-extinguishing material�Fully insulated�Metal graphite brushes�One-way insertion pin�Complete of 1.5m cable CEI 20-22 NPI
4conductors
TR8511
15
conductorsTR8512
70 A
trol
ley 4
conductorsTR8518 – TR8532 (articulated used for line with curved busbar)
15
conductorsTR8519
Dou
ble
trol
ley
supp
ort
�Connects two trolleysin parallel to increasecurrent rating
TR6013 1
Han
ger
calm
p
�Fast connection�Every 2 meters MAXfrom 40 to 140 amp�Every 1 meter MAXfor 200A
Pa66material
TR8502 (not for 200 A)
1Steel
materialTR8525
Fixe
dpo
int
TR8527.1 1
Gas
ketI
P23
Additional prot.IP13>IP23�PVC material�Resistance to cold:
-30°�Stretching 340%�Hardness shore A 81
TR8505 (●)
Tow
ing
arm
Fixed to the mobile device permits to tow the trolley�Galvanizedsteel material
TR8510 1
Tow
ing
arm
brac
ket
Fixed to the trolley permits to the mobile device to tow the trolley�Painted blacksteel material
TR6007 1
Insp
ecti
onjo
int
With multiple trolleysallows easy maintenance or replacement of trolleys
- TR8528 1
Stri
p in
sert
ion
trol
ley Specific tool to insert
easily the copper into the busbar
- TR8514 1
De-
coil
unit Specific tool to easily
unwind the copper rolls- TR8513 1
Brus
hes
Spare parts
35 A TR8517
1
70 A TR8520
Busbar systemEnergy and data transmission TR85 series 40-70-100-140-200A
55
Dimensions see pag 62
Note (●) “gasket IP23 quantity”: (for order please considertwice the length of the line)
� TR85 40-70-100-140-200 amp
Code table listpage 2/2
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Click!
3 Fix the busbar
Busbar systemEnergy and data transmission
56
Mounting instructions
1 Fix the support bars
�TR60 max 1.33 meters �TR85 from 40 A to 140 A max 2 meters �TR85 200 A max 1 meters
Yellow line(conductors to be pulled)
2 Fix the hanger clamp
�set vertical positions moving up and down the bolt and tighten well
�NO tools required
6 Pull the conductors4 Apply all the joints
�TR60 no tools required�TR85 fixed by screws
5 Fix the copper strip to the insertiontrolley
�Drill the copper strip if not already provided with holes and fix it to the insertion trolley
�Drag the trolley using a rope�Repeat the operation for all the coductors�Drag one conductor one by one
9 Insert the trolley7 Cut the copper strip
�Cut the copper strip 50mm out from the busbar(line feed side)�Cut the copper strip flush with the busbar(end cap side)
8 Prepare the trolleys
�TR60: to be cabled: wire the trolley respecting the connections shown�TR85 Trolleys are already supplied with the wire
�One way insertion pin / press in the brushes�PE brush corresponding to the continuous black line on the busbar side
10 Mount the feed
�Fix the case to the busbar�Bend and drill (if not already drilled) the strips�Cable the strips as shown/tight the cable gland
11 Mount the end cap
�Fix the end capwww.youtube.com/user/GiovenzanaInt
4c Close & fix the cover4a If needed mount the in-line feed
�Put both sides on the busbar�Pull & bend the copper conductors�Operation recommended to do before point 5
4b Cable the line
�Cable the strips as shown �Close and fix both cover�Tighten the cable gland
L 1
L 2NL 3
P E
E n d c a p s i d eF e e d s i d e
NL 2 L 3
L 1 P E
NEED HELP?Ask to our technical service
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3 Fix the busbar
Busbar systemEnergy and data transmission Mounting instructions
1 Fix the support bars
�TR60 max 1.33 meters �TR85 from 40 A to 140 A max 2 meters �TR85 200 A max 1 meters
Blue line(pre-mounted conductors)
2 Fix the hanger clamp
�set vertical positions moving up and down the bolt and tighten well
�NO tools required
4 Fix each conductors strip
�Fast connection using dedicated clamps
7 Insert the trolley
6 Prepare the trolleys
�TR60: to be cabled: wire the trolley respecting the connections shown�TR85 Trolleys are already supplied with the wire
8 Mount the feed
�Fix the conductors of each legs�Apply joint / cable the strips as shown�tight the cable gland and close with the cover
9 Mount the end cap
�Fix the end cap / apply joint
3c Close & fix the conver3a If needed mount the in-line feed 3b Cable the line
L 1
L 2NL 3
P E
NEED HELP?Ask to our technical service
57
5 Apply all the joints
�TR60 no tools required�TR85 fixed by screws
�One way insertion pin / press in the brushes�PE brush corresponding to the continuous black line on the busbar side
�Fix the conductors of each side�Apply joint
�Cable the strips as shown �Close and fix both cover�Tight the cable gland
NL 2 L 3
L 1 P E
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compatible with yellow line(conductors to be pulled)
Busbar systemEnergy and data transmission
58
TR60 Drawings & Dimensions
� TR6000 TR60 line busbar
compatible with blue line(pre-mountedconductors)
� TR60404C3-TR60405C3-TR60404C-TR60405C� TR60604C3-TR60605C3-TR60604C-TR60605C
TR60 line pre-mounted busbar
Line Amp N° conductors Bar length “L”
TR60 40= 40 amp60= 60 amp
4C = four5C= five
No extension = 4meters3= three meters complete of terminal clamp for each conductors
Radius[meters] 40 amp 60 amp
1.2 � TR60404A90 � TR60604A90
1.5 �TR60404B90 �TR60604B90
1.8 � TR60404C90 � TR60604C90
2.2 �TR60404D90 �TR60604D90
4 conductors only 90°
90°
Radius[meters] 40 amp
1.2 � TR60A90
1.5 �TR60B90
1.8 � TR60C90
2.2 �TR60D90
4 conductors only can be pulled
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compatible with yellow line(conductors to be pulled)
Busbar systemEnergy and data transmission
59
TR60 Drawings & Dimensions
� TR6001 TR60 line joint � TR6002 TR60 line hanger clamp
� TR6003 TR60 line feed
5x M5x8
2x 3.5x9.5 self tapping
M25
compatible with blue line(pre-mountedconductors)
� TR6003A4-TR6003A5 TR60 line pre-mounted feed
� TR6003A5 5 polesL1-L2-L3-N-PE� TR6003A4 4 poles
L1-L2-L3-PE
� TR6004 - TR6005 TR60 line trolley
�
TR6004
4 polesL1-L2-L3-PE
�
TR6005
5 polesL1-L2-L3-N-PE
connection rif. markings
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Busbar systemEnergy and data transmission
60
TR60 Drawings & Dimensions
complete of:• M25 cable gland• 5x terminal clamp
� TR6008 TR60 line in-line feed
2xM8x25
� TR6006 TR60 line end cap
� TR6007 TR60-85 line towing arm bracket
compatible with yellow line(conductors to be pulled)
compatible with blue line(pre-mountedconductors)
� TR6006A TR60 line pre-mounted end cap
� TR6008A4-TR6008A5 TR60 line pre-mounted in-line feed
�
TR6008A4
4 polesL1-L2-L3-PE
�
TR6008A5
5 polesL1-L2-L3-N-PE
complete of terminal clamp for each conductors
6x M25 closed spot
5x M25 closed spot
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compatible with yellow line(conductors to be pulled)
Busbar systemEnergy and data transmission
61
for order please consider twice the length of the line
TR60 Drawings & Dimensions
compatible with blue line(pre-mountedconductors)
� TR6012 TR60 line gasket IP23
� TR6013 TR60 line double trolley support
� TR6014 TR60 line fixed point
M8x50
� TR6011 TR60 line strip insertion trollety
� CS40
40 amp10 mm²
1 x 10 mm²
� CS60
60 amp15mm²
1.5 x 10 mm²
copper conductors
screw fix
� CS40-CS60 TR60 line copper strip
� TR6020 TR60 line hanger clamp (steel)
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Busbar systemEnergy and data trasmission
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TR85 Drawings & Dimensions
compatible with yellow line(conductors to be pulled)
compatible with blue line(pre-mountedconductors)
Radius[meters] 40 amp 70 amp 100 amp 140amp
1.2 � TR8529404A90 � TR8529704A90 � TR85291004A90 � TR85291404A90
1.4 � TR8529404B90 � TR8529704B90 � TR85291004B90 � TR85291404B90
1.8 � TR8529404C90 � TR8529704C90 � TR85291004C90 � TR85291404C90
2.2 � TR8529404D90 � TR8529704D90 � TR85291004D90 � TR85291404D90
4 conductors only 90°
90°
Radius[meters]
1.2 � TR8529A90
1.4 �TR8529B90
1.8 �TR8529C90
2.2 �TR8529D90
4 conductors only can be pulled
� TR85404C3-TR85405C3-TR85404C-TR85405C� TR85704C3-TR85705C3-TR85704C-TR85705C� TR851004C3-TR851005C3-TR851004C-TR851005C� TR851404C3-TR851405C3-TR851404C-TR851405C� TR852004C3-TR852005C3-TR852004C-TR852005C
TR85 line pre-mounted busbar
Line AmpN°
conductorsLength bar
“L”
TR85
40= 40 amp70= 70 amp100= 100 amp140= 140 amp200= 200 amp
4C = four5C= five
No extension = 4meters3= three meters
Line AmpN°
conductorsBar lenght
“L”
TR8570= 70 amp100= 100 amp140= 140 amp
4C = four5C= five
4meters
� TR85704-TR85705� TR851004-TR851005� TR851404-TR851405
TR85 line busbar
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compatible with yellow line(conductors to be pulled)
Busbar systemEnergy and data transmission
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TR85 Drawings & Dimensions
compatible with blue line(pre-mountedconductors)
� TR8501 TR85 line joint � TR8502 TR85 line hanger clamp
� TR8503 TR85 line feed � TR8503A4-TR6003A5� TR8533A4-TR8533A5
TR85 line pre-mounted feed
� TR8503A5(40…140amp)�TR8533A5
(200amp)
5 polesL1-L2-L3-N-PE
� TR8503A4(40…140amp)�TR8533A4
(200amp)
4 polesL1-L2-L3-PE
� TR8504-TR8535 TR85 line joint
� TR8505 TR85 line gasket IP23
� TR8506A TR85 line pre-mounted end cap
� TR8506 TR85 line end cap
� TR8510 TR60-85 line towing arm
for order please consider twice the length of the line
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compatible with yellow line(conductors to be pulled)
Busbar systemEnergy and data transmission
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TR85 Drawings & Dimensions
compatible with blue line(pre-mountedconductors)
� TR8511-TR8512 TR85 line 35 amp trolley
� TR8513 TR60-85 line de-coil unit
� TR8517-TR8520 TR85 line brush
� TR8518-TR8519-TR8532 TR85 line 70 amp trolley
�
TR8511
4 polesL1-L2-L3-PE
�
TR8512
5 polesL1-L2-L3-N-PE
Ø800
58
38
330
� TR8514 TR85 line strip insertion trolley
�
TR8517
for 35 amptrolley
�
TR8520
for 70 amptrolley
�
TR8518
4 polesL1-L2-L3-PE
�
TR8519
5 polesL1-L2-L3-N-PE
�Ball bearing wheels�Complete of L 1500mm CEI 20-22 NPI cable
�Ball bearing wheels�Complete of L 1500mm CEI 20-22 NPI cable
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TR8532
4 polesL1-L2-L3-PEarticulatedfor curves
TR6007
compatible with yellow line(conductors to be pulled)
Busbar systemEnergy and data transmission
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TR85 Drawings & Dimensions
compatible with blue line(pre-mountedconductors)
� TR8524 TR85 line joint (steel)
� TR8527.1 TR85 line fixed point � TR8528 TR85 line inspection joint
� TR8525 TR85 line hanger clamp (steel)
screw 8x70
� Used for maintenance operation, it allows easy removal of the trolley:1) disconnect the trolley to be removed2) place the trolley in the inspection joint3) remove the half joints and half busbar (side “A” without ribs)4) replace the trolley5) close the busbar and joints6) place the adhesive rubber gasket
side “A” without ribs
side “B”with ribs
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adhesive rubber gasket
compatible with yellow line(conductors to be pulled)
Busbar systemEnergy and data transmission
66
TR85 Drawings & Dimensions
compatible with blue line(pre-mountedconductors)
two arm clip kit included
�
TR8550
L= 350mm
�
TR8551
L= 500mm
�
TR8552
L= 700mm
� TR8555-TR8556 TR60-85 line support bracket (wall fixing)
�
TR8555
L= 350mm
�
TR8556
L= 500mm
� TR8550-TR8551-TR8552 TR60-85 line support bracket (rail fixing)
� TR8547 TR85 line in-line feed
Pg29 cable gland included(not mounted)
� TR8545-TR8545B TR85 line section joint
Insulating strip bars
�
TR8545
yellow
�
TR8545B
blue
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M o u n t i n g
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Busbar systemEnergy and data transmission
67
Technical data
General characteristics
Line / SizeTR60 TR85
40 60 40 70 100 140 200
Operating current 23°C 40A 60A 40A 70A 100A 140A 200A
Comply with standards CEI EN 60439-1, CEI EN 60439-2, CEI EN 60695-2-1, CEI EN 60570
Markings
Rated operating voltage [Ue] 600 Vac
Frequency 50 Hz
Conditional rated short circuit withstand current 10 kA
Fuse rating gG 40A 60A 40A 70A 100A 160A 200A
Protection class CEI EN 60529 IP13 (IP23 with gasket accessories)
Flammability resistance
UL94 V0
Cei EN 60695-2-1 [°C] 960
Ambienttemperature
operating -30 °C + 55 °C
storage -30 °C + 70 °C
Admissible trolley speed 200 m/min1
Copper strip section [mm²] 10 15 9.3 15.5 23.25 31 46.5
Resistance [Ω/m 10-4] 17 11.33 18.27 10.96 7.83 5.48 3.65
Impedence [Ω/m 10-4] 17.09 11.38 18.36 11.01 7.87 5.55 3.67
PVC busbar characteristics
Material rigid PVC
Self-extinguish
UL 94 V0
DIN 4102 B2
D.M.6/7/83 CI
Ultimate tensile strenght ISO R527 23 °C 430 kg/cm3
Yield point ISO R527 23 °C 460 kg/cm2
Modulus of elasticity ISO R178 23 °C 30000 kg/cm2
Impact resistance DIN 53453 unbroken
Dielectric strenght ASTM 149 25 kV/mm
Softening temparature – Vicat ISO R306 49N 82 °C
Conductors bars weight table (complete of conductors)
Line / SizeTR60 TR85
40 60 40 70 100 140 200
N° of conductors
4 1.035 kg/m 1.219 kg/m1.680 kg/m
1.902 kg/m
2.122 kg/m
2.454 kg/m
3.010 kg/m
5 1.127 kg/m 1.357 kg/m1.764 kg/m
2.050 kg/m
2.305 kg/m
2.730 kg/m
3.423 kg/m
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Festoon system – line 30 – 41 and 41 inox Giovenzana page 68 to 79
The festoon system is the traditional system for energy transmission for various type of handling equipment. One of the most popular is the overhead crane where the festoon lines transmit the signals to control the movement of the crane.Line 30 and 41 Giovenzana are made of a “C”- rail bar fixed along the crane’s movement line. The signal cable is supported by the trolley that slides inside the “C”-rail bar.Both lines 30 and 41 offer a complete selection of items and accessories to customize them according Customer needs.
Typical line schematic:
ID Picture Name
① C-rail bar
②Support arm and support bracket
③ Towing trolley
④ Trolley
⑤ Joint
Festoon line module type
Straight:4 meters module
(3 meters for stainless steel)
Curve: 90° curve radius 1.5 m(only line 41)
Festoon systemEnergy and data transmission
C- rail bar system
Line Characteristic Markings
30 � Bar height: 30 mm � Load capacity: 100 kg/m
41 � Bar height: 41 mm � Load capacity :140 kg/m
41 stainless steel � Bar height: 41 mm � Load capacity :140 kg/m � Stainless steel material
⑥ Head clamp
⑦ End Cap
⑧ Cable
⑨ End stop
①
③
④
②
⑤
⑥
⑦⑨
⑧
⑦⑨
product descriptionLine 30 – 41 – 41 stainless steel
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Line 30-41Code table listFestoon system
Energy and data transmission
Description note
Line 30 (load capacity 100 kg/m Line 41 (load capacity 140 kg/m)Min. qtyCode Picture
Codestandard
Codestainless steel
Picture
C-Rail bar
straight 4m 30607001 30602001/4 30602061 (3m)3-4
meters90° curved radius 1.5 m - 30602054 (○) -
Track support bracket 30607017 30602004 - 1
Track support bracket 30607003 30602003 30602063 1
Joint
standard 30607002 30602002 30602065
130602034 30602062double for
track >50m -
End stop 30607005 30602038 30602068 1
Towing trolley
single execution 30607007 30602091 30602067
1double
execution - 30602020 -
Trolley with safety plug and socket connection
16 poles 30607008 30602036 -1
24 poles 30607019 30602040 -
Trolley (steel)
ball bearing wheels 30607010 30602086 -
10PA
wheels 30607009 - -
Trolley (PA)
55 mm saddle 30607011 30602069 30602064
1076 mm saddle - 30602070 -
Round cable trolley PA/steel 30607021 - - - 10
Head clamp
55mm saddle 30607020 30602071 30602066
176mm saddle 30607006 30602072 -
Bracket
500 mm 30607001/05 - -- 1
800 mm 30607001/08 - -
Support arm bracket (hanger) 30607004 - - - 1
Support arm clip (claw) 30607012 - - - 1
End cap 30607015 - - - 1
Cable clip 30607016 - - - 10
(○) may requiremechanical adjustment during line assembly
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Picture Description Code Dimensions
C-Rail bar�Material: galvanized steel�Length: 4 m�Weight: 5 kg
30607001
Bracket�Material:
galvanized steel
30607001/05(length 0.5 m)30607001/08(length 0.8 m)
Jointto connect a C-rail and suitable for supporting the track�Material: galvanized steelScrews M5x10 included
30607002
Track support bracket2 pcs�Material: galvanized steel�Max support spacing: 1 mscrews not included
30607003
Support arm bracket (hanger)�Material: galvanized steel�Max support spacing: 1 m
30607004
End stop�Material: PA6
30607005
Line 30Load capacity: 100 kg/m - drawings & dimensionsFestoon system
Energy and data transmission
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Line 30Load capacity: 100 kg/m - drawings & dimensionsFestoon system
Energy and data transmission
Picture Description Code Dimensions
Head clamp�Material: PA
30607020(55 mm saddle)
30607006(76 mm saddle)
Towing trolley�Material: galvanized steel�Steel rollers with ball-bearing�68 mm steel saddle
30607007
Trolley with safety plug and socket connectionTo connect the festoon system to the pendant station�68 mm saddle
30607008(16 poles)
30607019(24 poles)
Trolley (steel)�Material: galvanized steel�68 mm steel saddle
30607009(PA wheels)30607010
(ball-bearing wheels)
Trolley (PA)�Material: PA�PA rollers�55 mm PA material saddle
30607011
Support arm clip (claw)�Material: galvanized steel(need n° 2 for every bracket)
30607012
71
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X:93 for 16poles
120 for 24poles
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Line 30Load capacity: 100 kg/m - drawings & dimensionsFestoon system
Energy and data transmission
Picture Description Code Dimensions
End cap 30607015
Cable clip 30607016
Track support bracketCeiling fixing 2 pcs�Material: galvanized steel�Max support spacing: 1 mscrews not included
30607017
Round cable trolley�Galvanized steel trolley upper body with PA saddle�Steel rollers with ball-bearing�Swinging & rotating saddle�Cable diameter:
min 10 – MAX 40 mm
30607021
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Picture Description Code Dimensions
C-Rail bar�Material: galvanized steel�Length: 4 m�Weight: 8 kg
30602001/4
90° curved bar�1.5 meters radiusmay require mechanical adjustmentduring line assembly
30602054
Jointto connect a C-rail and suitable for supporting the track�Material: galvanized steelScrews M5x10 included:No. 4 for singleNo. 8 for doubleUse double for track >50meters
30602002(standard)30602034(double)
Track support bracket2 pcs�Material: galvanized steel�Max support spacing: 1 mscrews not included
30602003
Track support bracketCeiling fixing 2 pcs�Material: galvanized steel�Max support spacing: 1 mscrews not included
30602004
Towing trolley�Material: galvanized steel�steel rollers with ball-bearing�68 mm steel saddle
30602091(single)
30602020(double)
Line 41 standardLoad capacity: 140 kg/m - drawings & dimensionsFestoon system
Energy and data transmission
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double
standard
double
Top view
single
single
double
73doublesingle
Festoon systemEnergy and data transmission
Picture Description Code Dimensions
Trolley with safety plug and socket connectionTo connect the festoon system to the pendant station�68 mm steel saddle
30602036(16poles)30602040(24poles)
End stop�Material: PA6
30602038
Trolley (PA)�Material: PA�PA rollers�55 or 76 mm PA saddle
30602069(55 mm saddle)
30602070(76 mm saddle)
Head clamp�Material: PA�55 or 76 mm PA saddle
30602071(55 mm saddle)
30602072(76 mm saddle)
Trolley (steel)�Material: galvanized steel�68 mm steel saddle
30602086
Line 41 standardLoad capacity: 140 kg/m - drawings & dimensions
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X:93 for 16poles
120 for 24poles
Festoon systemEnergy and data transmission
Picture Description Code Dimensions
ST
AIN
LES
S S
TE
EL
C-Rail bar�Material: stainles steel�Length: 3 m�Weight: 8 kg
30602061
ST
AIN
LES
S S
TE
EL Joint
to connect a C-rail and suitable for supporting the track�Material: stainless steelstainless screws M5x10 includedNo. 4 for singleNo. 8 for doubleUse double for track >50meters
30602065(standard)30602062(double)
ST
AIN
LES
S S
TE
EL
Track support bracket2 pcs�Material: stainless steel�Max support spacing: 1 mscrews not included
30602063
ST
AIN
LES
S S
TE
EL
Trolley (PA)�Material: PA�PA rollers�55 mm PA material saddle
30602064
ST
AIN
LES
S S
TE
EL
Head clamp�Material: PA - stainless steel�55 mm PA material saddle
30602066
ST
AIN
LES
S S
TE
EL
Towing trolley�Material: PA - stainless steel�steel rollers with ball-bearing�55 mm steel saddle
30602067
ST
AIN
LES
S S
TE
EL
End stop�Material:PA6 – stainless steel screw
30602068
Line 41 stainless steelLoad capacity: 140 kg/m - drawings & dimensions
75
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double
singlesingle
double
76
Festoon system – line wire-rope Giovenzana page 76
The festoon system is the traditional system for energy transmission for various type of handling equipment.Line wire-rope Giovenzana uses a rope to support the trolleys carrying the cable that supplies energy to the mobile device.
Festoon systemEnergy and data transmission
Wire -rope system
Line Characteristic Markings
Wire-rope Rope diameter:8 mm
Travel speed:40 m/min.
Trolley type:for flat or round cable
Trolley loadcapacity: 8 kg
Picture Description CodeMin. qty
Dimensions
FLAT CABLE
Twin roller trolley�Material:
PA6- galvanized steel�Type of roller: PA�Rotating 55 mm
plastic saddle�Range 30 mm�Speed 40 m/min.
30604003 10
FLAT CABLE
One roller trolley�Material:
PA6- galvanized steel�Type of roller: PA�Rotating 55 mm
plastic saddle�Range 30 mm�Speed 40 m/min.
30604005 10
ROUND CABLE
One roller trolley+ metal cable clip�Material:
PA6- galvanized steel�Type of roller: PA�Cable Ø max: 18 mm�Speed 40 m/min.
30604007 10
product description - contenentsLine wire-rope
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Festoon system – line I-beam Giovenzana page 77 - 78
The festoon system is the traditional system for energy transmission for various types of handling equipments.Line I-beam Giovenzana uses the beams of the mobile device to support the trolleys carrying the cable that supplies energy to the mobile device.Line I-beam Giovenzana is suitable for installation in industries where heavy duty capabilities are required.For example it is used in:powering mobile equipment in steel mills, cranes, rolling mills, foundries, storage containers, etc… .
77
Festoon systemEnergy and data transmission
I-beam system
Line Characteristic Markings
Light series Beam type:IPE-IPN 80÷100
Travel speed:120 m/min.
Trolley load capacity:50 kg
Max cable capacity:70 mm
product description - contenentsLine I-beam
IPN
IPE
I-beamtype
I-beamsize
Seddle[mm]
Rollers TrolleyTowingtrolley
Headclamp
IPE
80
55PA 30606003 30606033
30606062steel 30606103 30606133
85PA 30606005 30606035
30606063steel 30606105 30606135
100
55PA 30606011 30606041
30606066steel 30606111 30606141
85PA 30606013 30606043
30606067steel 30606113 30606143
IPN
80
55PA 30606004 30606034
30606062steel 30606104 30606134
85PA 30606006 30606036
30606063steel 30606106 30606136
100
55PA 30606012 30606042
30606066steel 30606112 30606142
85PA 30606014 30606044
30606067steel 30606114 30606144
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Festoon systemEnergy and data transmission dimensions
Line I-beam
Light series
Trolley
Towing trolley
Head clamp
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Festoon systemEnergy and data transmission Line diagram
Line calculating schematic
Example “1" (blue colour) Total line length "LT" = 40 metersHeight "H" = 2 meters
Number of trolley/trucks = 12 pcs
Parking zone length "LP" = 1,2 metersRace length "LC=LT-LP" = 38,8 meters
Example “2" (red colour) Total line length "LT" = 40 metersHeight "H" = 1 meters
Number of trolley/trucks = 21 pcs
Parking zone length "LP" = 2,2 metersRace length "LC=LT-LP" = 37,8 meters
Line diagram
The diagram is used to determine the number of trolley necessary for the formation of the line, depending on its lenght.The height of the loop determines how many trolley are needed and thus their parking area. Where the parking area is toolong at the expense of running real user, it must increase the height of the loops, thus decreasing the number of trolleysrequired and therefore the parking area. To determine the cable lenght of a garland to increase by 10% the total lenght ofthe line and add enought to connect the two ends of the fixed and mobile users.
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Body disconnector switch base fixing page 82
Used to disconnect the power supply for maintenance operations. The door-interlock actuator comes with a locking knob, which can work with 3 locks (max) in complete safety. It is available in different size according to line range.
82
Festoon & Busbar systemEnergy and data transmission Complementary products
Disconnector switch
Characteristic
Code SQ032003B SQ063003B SQ125003B
Product ID SQ32 – Giovenzana Line SQ63 – Giovenzana Line SQ125 – Giovenzana Line
Picture
Functiondoor interlock - 3 poles on-off – 90° switching angle
(aux contact : neutral, protective earth “PE”, NC or NO available on request)
Comply with standards IEC 947-3, EN60947-3, UL508
Rated insulation voltage [Ui] 690V
Rated impulse withstand voltage [Uimp] 8kV
Rated thermal current [Ith] / in enclosed [Ithe] 40A 80A 125A
Frequency 50/60 Hz
Rated operating current [Ie]
AC21A 690Vac 40A 80A 125A
AC22A 690Vac 32A 80A 125A
AC23A 3ph-3poles
230V 32A 75A 125A
400/500V 32A 67A 125/100A
690V 20A 32A 80A
Rated breaking capacity (cosϕ 0.45) 400V 256A 536A 1000A (cosϕ 0.35)
Conditional rated short circuit 10kA 10.5kA
Fuse ratings gG 690V 40A 63A 125A
Connectable sectionflex cable 1.5 - 10 mm² 6 - 25 mm² 10-70 mm²
rigid cable 1.5-16 mm² / 12-6 AWG 10-35 mm² / 10-2 AWG 10-70 mm²
General use UL 508 600Vac 40A 80A -
Terminal protection class IP20 - (IP10 for SQ125)
Fixing system DIN-rail 50022-35 or with screws
Dimensions
Series A B C D E F G L
SQ032 45 52.6 22 60 12.5 13.5 60.3 80÷142 max
SQ063 52.5 72.5 43.5 82.5 17.5 23.5 57.8 112÷142 max
SQ125 65.2 92 51.2 102.2 22.5 16 64 127÷327 max
for series code
SQ032 012/0001 (○)
SQ063 042/0001 (○)
SQ125 231/0001
Door-interlock actuator
�Yellow front plate
�Red knob
�Locking knob (max 3 locks)
�Protection class EN60529: IP65
(○) UL50 type 1-4-4x
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